Powered surgical instrument

ABSTRACT

A surgical instrument including a housing, an endoscopic portion, a shaft portion and an end effector is disclosed. The endoscopic portion extends distally from the housing and defines a longitudinal axis. The shaft portion is selectively connectable to a distal end of the endoscopic portion. The end effector is selectively connectable to a distal end of the shaft portion.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.17/494,419, filed Oct. 5, 2021, now U.S. Pat. No. 11,324,499, which is acontinuation of U.S. patent application Ser. No. 17/318,746, filed May12, 2021, now U.S. Pat. No. 11,259,802, which is a continuation of U.S.patent application Ser. No. 16/846,602, filed Apr. 13, 2020, which is acontinuation of U.S. patent application Ser. No. 16/523,387, filed Jul.26, 2019, now U.S. Pat. No. 10,653,416, which is a continuation of U.S.patent application Ser. No. 15/151,625, filed May 11, 2016, now U.S.Pat. No. 10,524,785, which is a continuation of U.S. patent applicationSer. No. 11/894,959, filed on Aug. 21, 2007, now abandoned, which is aContinuation-in-Part Application of U.S. patent application Ser. No.11/786,934, filed on Apr. 13, 2007, now U.S. Pat. No. 7,950,560, theentire contents of each of which is hereby incorporated by referenceherein.

BACKGROUND Technical Field

The present disclosure relates to surgical instruments for fasteningbody tissue and, more particularly, to a powered surgical instrumenthaving a drive gear configured to be movable to affect rotation,articulation and actuation of the instrument.

Background of Related Art

Surgical devices wherein tissue is first grasped or clamped betweenopposing jaw structure and then joined by surgical fasteners are wellknown in the art. In some instruments, a knife is provided to cut thetissue which has been joined by the fasteners. The fasteners typicallyinclude surgical staples and two part polymeric fasteners.

Instruments for this purpose may include two elongated members which arerespectively used to capture or clamp tissue. Typically, one of themembers carries a staple cartridge that houses a plurality of staplesarranged in rows while the other member has an anvil that defines asurface for forming the staple legs as the staples are driven from thestaple cartridge. Several instruments include clamps, handles and/orknobs to affect actuation along with rotation and articulation of an endeffector. Such surgical instruments can require the user to exert asignificant force in operating the handles, knobs, etc., and requiremore than one hand to operate the instrument.

Surgical instruments with actuators that require less force to operateare desired. In addition, surgical instruments which perform multiplefunctions with one handed operation are also desired.

SUMMARY

The present disclosure relates to a surgical instrument including ahousing, an endoscopic portion, a drive gear, a drive motor, a shiftmotor and an end effector. The endoscopic portion extends distally fromthe housing and defines a longitudinal axis. The drive gear is disposedat least partially within the housing and is rotatable about a drivegear axis which extends therethrough. The drive gear is selectivelymovable along the drive gear axis. The drive motor is disposed inmechanical cooperation with the drive gear and is configured to rotatethe drive gear. The shift motor is disposed in mechanical cooperationwith the drive gear and is configured to move the drive gear along thedrive gear axis. The end effector is disposed adjacent a distal portionof the endoscopic portion.

The present disclosure also relates to a method of applying surgicalfasteners to tissue. The method of this embodiment includes providing apowered surgical instrument which includes a housing, an endoscopicportion, a drive gear and an end effector. The endoscopic portionextends distally from the housing and defines a longitudinal axis. Thedrive gear is disposed at least partially within the housing and isrotatable about a drive gear axis extending therethrough. The drive gearis selectively movable along the drive gear axis. The end effector isdisposed adjacent a distal portion of the endoscopic portion. The methodfurther includes moving the drive gear along the drive gear axis androtating the drive gear about the drive gear axis.

DESCRIPTION OF THE DRAWINGS

An embodiment of the presently disclosed powered surgical instrument isdisclosed herein with reference to the drawings, wherein:

FIG. 1 is a perspective view of a powered surgical instrument accordingto an embodiment of the present disclosure;

FIG. 2 is an enlarged partial perspective view of the powered surgicalinstrument of FIG. 1;

FIG. 3 is an enlarged partial perspective view of the powered surgicalinstrument of FIGS. 1 and 2;

FIG. 4 is a partial perspective sectional view of internal components ofthe powered surgical instrument of FIGS. 1-3 in accordance with anembodiment of the present disclosure;

FIGS. 5 and 6 are partial perspective sectional views showing theinternal components of the powered surgical instrument of FIGS. 1-4disposed in a first position;

FIG. 7 is a cross-sectional view of the internal components of thepowered surgical instrument of FIGS. 1-5 disposed in a second position;

FIG. 8A is a partial perspective view including an endoscopic portion ofthe powered surgical instrument of FIGS. 1-7 according to an embodimentof the present disclosure;

FIG. 8B is an enlarged perspective view of a portion of the poweredsurgical instrument indicated in FIG. 8A;

FIGS. 9-11 are partial perspective sectional views of the internalcomponents of the powered surgical instrument of FIGS. 1-8 disposed in athird position;

FIGS. 12 and 13 are enlarged perspective views of portions of thepowered surgical instrument of FIGS. 1-11 according to an embodiment ofthe present disclosure;

FIG. 14 is a cross-sectional view of a portion of a powered surgicalinstrument including a handle portion according to an embodiment of thepresent disclosure;

FIGS. 15A-B are perspective views of an articulating shaft of the distalportion of the powered surgical instrument of FIG. 1 according to anembodiment of the present disclosure;

FIG. 16 is a perspective view of a powered surgical instrument having aselectively connectable shaft portion according to an embodiment of thepresent disclosure;

FIGS. 17A-17C are each perspective views of end effector having circularstaple cartridges engaged with a shaft portion, each shaft portion beingconnectable with the powered surgical instrument of FIG. 16;

FIG. 18 is a perspective view of an end effector having parallel jawmember engaged with a shaft portion, the shaft portion being connectablewith the powered surgical instrument of FIG. 16; and

FIG. 19 is a rear perspective view of the powered surgical instrument ofFIG. 16.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments of the presently disclosed powered surgical instrument arenow described in detail with reference to the drawings, in which likereference numerals designate identical or corresponding elements in eachof the several views. As used herein the term “distal” refers to thatportion of the powered surgical instrument, or component thereof,farther from the user while the term “proximal” refers to that portionof the powered surgical instrument or component thereof, closer to theuser.

A powered surgical instrument, e.g., a surgical stapler, in accordancewith the present disclosure is referred to in the figures as referencenumeral 100. Referring initially to FIG. 1, powered surgical instrument100 includes a housing 110, an endoscopic portion 140 defining alongitudinal axis A-A extending therethrough, and an end effector 160,defining a longitudinal axis B-B (illustrated substantially aligned withaxis A-A in FIG. 1) extending therethrough. Endoscopic portion 140extends distally from housing 110 and end effector 160 is disposedadjacent a distal portion 142 of endoscopic portion 140.

With reference to FIGS. 2 and 3, an enlarged view of housing 110 isillustrated according to an embodiment of the present disclosure. In theillustrated embodiment, housing 110 includes a handle portion 112 havingat least one button 114 thereon (two buttons 114 a and 114 b are shown).Handle portion 112, which defines a handle axis H-H, is shown havingindentations 116 that correspond to fingers of a user. Each button 114 aand 114 b is shown as being disposed on an indentation 116 to facilitateits depression by a user's finger.

With continued reference to FIGS. 2 and 3, a proximal area 118 ofhousing 110 includes a user interface 120. In the illustratedembodiment, user interface 120 includes a screen 122 and at least oneswitch 124 (seven switches 124 a-124 g are shown). Screen 122 displaysreadable information thereon, including status information of poweredsurgical instrument 100 in an embodiment. Switches 124 a-124 g controlvarious actions of powered surgical instrument 100, as is described indetail below.

FIGS. 4-7, 9-11 and 14 illustrate various internal components of poweredsurgical instrument 100, including a drive gear 200 or drive member, adrive motor 210 and a shift motor 220. It is envisioned that athree-position solenoid, for instance, can be used as an alternative toshift motor 220. Drive gear 200 is rotatable about a drive gear axis C-Cextending therethrough (FIG. 4) and is selectively movable along drivegear axis C-C. Drive motor 210 is disposed in mechanical cooperationwith drive gear 200 and is configured to rotate drive gear 200 aboutdrive gear axis C-C.

Shift motor 220 is disposed in mechanical cooperation with drive gear200 (drive motor 210 is illustrated between drive gear 200 and shiftmotor 220 in accordance with a disclosed embodiment) and is configuredto translate drive gear 200 axially along drive gear axis C-C. In adisclosed embodiment, drive motor 210 and/or shift motor 220 may be amotor or a gear motor, which may include gearing incorporated within itshousing. Shift motor 220 is configured to selectively move drive gear200 between a plurality of positions; three positions are shown in theillustrated embodiments. The first position, illustrated in FIGS. 5 and6, enables rotation of end effector 160; the second position,illustrated in FIG. 7, enables articulation of end effector 160; and thethird position, illustrated in FIGS. 9-11 and 14, enables actuation ofpowered surgical instrument 100.

A cut-away view of drive motor casing 212, surrounding drive motor 210,is illustrated in FIGS. 4-7, 9-10 and 14. Drive motor casing 212includes a plurality of slots 214 (three slots 214 a, 214 b and 214 care illustrated) therein. Each slot 214 is matable with a position lock216 to maintain drive gear 210 in a desired position. For example, inFIG. 5, position lock 216 is shown mated with slot 214 a—correspondingto drive gear 200 being in its first position. In FIG. 7, position lock216 is shown mated with slot 214 b—corresponding to drive gear 200 beingin its second position. FIGS. 9, 10 and 14 illustrate position lock 216mated with slot 214 c-corresponding to drive gear 200 being in its thirdposition. Position lock 216, in the illustrated embodiments, isspring-loaded towards drive motor casing 212, which helps place andmaintain drive motor 210 is a desired position.

In the illustrated embodiments, shift motor 220 is located proximally ofdrive motor 210 and is configured to translate drive motor 210 alongdrive gear axis C-C between its first, second and third positions.Referring to FIG. 10, shift motor 220 is illustrated as driving a shiftscrew 222 in conjunction with an internally-threaded screw housing 223(see FIG. 10), in accordance with a disclosed embodiment. It is furtherdisclosed that a shift sensor 224 (see FIG. 4) (e.g., micro switch oroptical/ferromagnetic proximity sensor activated by position lock 216),disposed adjacent position lock 216, electrically communicates with atleast one switch 124 to start or stop shift motor 220 and/or providesfeedback relating to the position of drive motor 210, for example themode of operation for powered surgical instrument 100 is desirablydisplayed on screen 122. For instance, the position of drive motor 210may be indicated on screen 122 of user interface 120.

With reference to FIGS. 5 and 6, the first position of drive gear 200 isillustrated. Here, a ring gear 230 or rotation member is disposed withinhousing 110 and rotation of ring gear 230 causes rotation of endoscopicportion 140, end effector 160 and a distal housing portion 110 a ofpowered surgical instrument 100. It is envisioned that an inner surfaceof ring 230 includes threads and/or teeth to engage drive gear 200, andis attached to distal housing portion 110 a, which is disposed distallyof a proximal housing portion 110 b. Further, distal housing portion 110a is rotatable with respect to proximal housing portion 110 b via aperipherally disposed channel 232 disposed within distal housing portion110 a and a corresponding peripherally disposed flange 234 disposedwithin proximal housing portion 110 b.

In an embodiment, ring gear 230 is rigidly secured within distal housingportion 110 a and is matingly engageable with drive gear 200. Thus,rotation of drive gear 200 causes ring gear 230, and thus distal housingportion 110 a to rotate. In FIG. 2, a lip 235 is shown which isolates auser's hand from rotatable distal housing portion 110 a. It isenvisioned that a plurality of washers or ball-bearings (possibly madefrom synthetic resinous fluorine-containing polymers sold under thetrademark Teflon®) are disposed between distal housing portion 110 a andproximal housing portion 110 b to reduce the rotational frictiontherebetween.

With continued reference to the embodiment illustrated in FIG. 6, aplurality of detents 231 is disposed around a surface 233 of distalhousing portion 110 a. A tab 237 is shown disposed on proximal housingportion 110 b and may comprise a pawl or spring-biased member. In adisclosed embodiment, tab 237 is distally biased and in mechanicalcooperation with at least one of plurality of detents 231. Thecombination of detents 231 and tab 237 helps secure distal housingportion 110 a in a rotational position with respect to proximal housingportion 110 b. Further, detents 231 and tab 237 may be provided to givethe user audible and/or tactile feedback when endoscopic portion 140 isrotated. In a disclosed embodiment, a three-position solenoid may beused to lock the rotational position of end effector 160 once thedesired rotational position is selected.

In FIG. 7, drive gear 200 is illustrated in its second position, asposition lock 216 is aligned with slot 214 b. Here, drive gear 200 ismatingly engaged with an articulation gear 240, which is disposed atleast partially within housing 110. Rotation of articulation gear 240causes end effector 160 to move from its first position, wherelongitudinal axis B-B is substantially aligned with longitudinal axisA-A, towards a position in which longitudinal axis B-B is disposed at anangle to longitudinal axis A-A. Preferably, a plurality of articulatedpositions are achieved.

In the illustrated embodiments and with specific reference to FIGS. 7and 8, articulation of end effector 160 is affected by an articulationgear 240, an articulation screw 242, an articulation linkage 244 and atleast one articulation rod 260. More specifically, articulation gear 240is rigidly mounted to articulation screw 242, such that as articulationgear 240 is rotated by rotation of drive gear 200 while in its secondposition, articulation screw 242 also rotates. A plurality of bearings262 is illustrated at various locations on articulation screw 242 tofacilitate the retaining and aligning of articulation screw drive 242 aswell as reducing the friction between articulation screw 242 and housing110, for example.

With continued reference to FIG. 7, articulation screw 242 includes athreaded portion 246, which extends through an internally-threadedportion 248 of articulation linkage 244. This relationship betweenarticulation screw 242 and articulation linkage 244 causes articulationlinkage 244 to move distally and/or proximally (in the directions ofarrows D and E) along threaded portion 246 of articulation screw 242upon rotation of articulation screw 242. For example, as articulationscrew 242 rotates in a first direction (e.g., clockwise), articulationlinkage 244 move proximally, and as articulation screw 242 rotates in asecond direction (e.g., counter-clockwise), articulation linkage 244move distally.

At least one articulation arm 250 is shown extending from articulationlinkage 244. In an embodiment, articulation arm 250 is rigidly connectedto articulation rod 260 and it is envisioned that more than onearticulation arm 250 is connectable to more than one articulation rod260. As articulation linkage 244 is translated distally and/orproximally in response to rotation of articulation gear 240,articulation rod(s) 260 is also translated distally and/or proximally(in the directions of arrows F and G, along longitudinal axis A-A) inresponse thereto. Any combinations of limits switches, proximity sensors(e.g., optical and/or ferromagnetic), linear variable displacementtransducers and shaft encoders (disposed within housing 110, forinstance) may be utilized to control and/or record the location ofarticulation linkage 244 and/or articulation angle of end effector 160and/or position of a firing rod 306 (as discussed below with referenceto FIGS. 9 and 11).

With reference to FIGS. 8A and 8B, articulation rod 260 is shownextending through at least a portion of endoscopic portion 140 and inmechanical cooperation with a linkage rod 264. Thus, linkage rod 264similarly moves along longitudinal axis A-A upon rotation ofarticulation gear 240. A distal portion 266 of linkage rod 264 is inmechanical cooperation with end effector 160, such that proximal anddistal movement of linkage rod 264 causes end effector 160 to move fromits first position towards its second position about pivot P. Forexample, linkage rod 264 is connected to end effector 160 at a locationoffset laterally from pivot P. More specifically, and for illustrativepurposes, as linkage rod 264 moves distally, end effector 160 isarticulated in the direction of arrow H and as linkage rod 264 istranslated proximally, end effector 160 is articulated in the directionof arrow I. It is also envisioned that a portion of articulation rod 260is in mechanical cooperation with end effector 160 to affectarticulation thereof. Further details of providing articulation to endeffector 160 are described in detail in commonly-owned U.S. Pat. No.6,953,139 to Milliman et al., the contents of which are herebyincorporated by reference in their entirety.

According to an embodiment of the present disclosure, end effector 160includes a cartridge assembly (e.g., jaw member 164) and an anvilassembly (e.g., jaw member 162) including an anvil portion for deployingsurgical fasteners into body tissue and forming the surgical fasteners.End effector 160 is pivotably mounted about an axis substantiallyperpendicular to the longitudinal axis of endoscopic portion 140.Cartridge assembly 164 houses a plurality of staples. Anvil assembly 162is movable in relation to cartridge assembly 164 between an openposition spaced from cartridge assembly 164 and an approximated orclamped position in juxtaposed alignment with cartridge assembly 164.Preferably, the staples are housed in cartridge assembly 164 to applylinear rows of staples to body tissue. End effector 160 is attached to amounting portion, which is pivotably attached to a body portion. Thebody portion may be integral with endoscopic portion 140 of poweredsurgical instrument 100, or may be removably attached thereto to providea replaceable or disposable loading unit. The loading unit may beconnectable to endoscopic portion 140 through a bayonet connection. Itis envisioned that the loading unit has an articulation link connectedto the mounting portion of the loading unit and the articulation link isconnected to the linkage rod so that the end effector 160 is articulatedas the linkage rod is translated in the distal-proximal direction alongthe longitudinal axis. Other means of connecting end effector 160 toendoscopic portion 140 to allow articulation may be used. For example, aflexible tube or a plurality of pivotable members may be used.

A loading unit may incorporate (or be configured to incorporate) variousend effectors, such as vessel sealing devices, linear stapling devices,circular stapling devices, cutters, etc. Such end effectors may becoupled to endoscopic portion 140 of powered surgical instrument 100. Anintermediate flexible shaft 500 may be included between handle portion112 and loading unit. For example, as shown in FIGS. 15A-B, endoscopicand distal portions 140, 142 are shown as a flexible shaft 500. Flexibleshaft 500 includes a plurality of interconnected angled outer tubes 501and 502. FIG. 15A shows flexible shaft in a non-articulated formationand FIG. 15B shows flexible shaft 500 in an articulated formation. Whenflexible shaft 500 is straight, narrow sections of tubes 501 alternatewith the wide sections of tubes 502 as shown in FIG. 15A. When flexibleshaft 500 is fully articulated, the short sides and the wide sides oftubes 501 and 502 are aligned, as shown in FIG. 15B. Such a flexibleshaft 500 may facilitate access in certain areas of the body.

Further, where various loading units can be used, a digital controlmodule (DCM) 130 (FIG. 4) can control the force being applied to rod 306so that rod 306 can drive the particular end effector that is on theloading unit in use at the time. For clarity, wires are not shown in theFigures connecting DCM 130 to various components of powered surgicalinstrument 100, but such wires are contemplated by the presentdisclosure. The loading unit may also include a mechanical or electronicsensor that indicates to DCM 130 which end effector is on the loadingunit. In an embodiment, DCM 130 is also capable of storing informationrelating to the force applied to rod 306. Additionally, the voltage andcurrent from drive motor 210 may be measured to provide informationand/or feedback regarding the state of powered surgical instrument 100.For instance, if the user is attempting to clamp down on tissue that istoo thick, the voltage and/or current will increase. This informationcan be provided to the user and/or the power can be interrupted orceased. It is envisioned that such a feature helps prevent damage to themechanisms in the instrument.

With reference to FIGS. 9-11 and 14, drive gear 200 is illustrated inits third position, with position lock 216 aligned with slot 214 c.Here, drive gear 200 is matingly engaged with an actuator gear 300,which is disposed at least partially within housing 110. Morespecifically, a set of teeth 202 disposed on a face 204 (FIG. 4) ofdrive gear 200 matingly engage teeth on actuator gear 300 to provide atleast one of grasping tissue, clamping tissue, and firing of endeffector 160 (e.g., stapling and cutting) and retracting elements totheir original position.

With continued reference to FIGS. 9 and 11, a drive tube 302, a bung 304and firing rod 306 are also included. Drive tube 302 includes internalthreads (not explicitly shown) along at least a portion of its lengthand is rigidly attached to actuator gear 300. Bung 304 is threadablyengaged with internal threads of drive tube 302 and is translatablewithin drive tube 302 with respect to actuator gear 300. FIG. 9 showsbung 304 near its proximal-most position and FIG. 11 illustrates bung304 near its distal-most position. Firing rod 306 is rigidly connectedto bung 304 and extends distally therefrom. In an embodiment of thedisclosure, firing rod 306 extends at least to distal portion 142 ofendoscopic portion 140.

In response to rotation of drive gear 200, actuator gear 300 and drivetube 302 also rotate. As drive tube 302 rotates, bung 304 and firing rod306 are translated proximally and/or distally within the confines ofdrive tube 302. Distal translation of firing rod 306 (corresponding witha clockwise rotation of drive gear 200, for instance) can cause jawmembers 162, 164 (see FIG. 1) of end effector 160 to grasp or clamptissue held therebetween. Additional distal translation of firing rod306 may cause surgical fasteners to be ejected from end effector 160(e.g., via cam bars and/or an actuation sled (neither of which areexplicitly shown in this embodiment)) to fasten tissue and may alsocause a knife (not explicitly shown in this embodiment) to sever tissue.Proximal translation of firing rod 306 (corresponding with acounter-clockwise rotation of drive gear 200, for instance) can causejaw members 162, 164 and/or knife to return to their pre-firedpositions. Further details of firing and otherwise actuating endeffector 160 are described in detail in commonly-owned U.S. Pat. No.6,953,139 to Milliman et al., the entire contents of which are herebyincorporated by reference herein.

In an embodiment of the disclosure, the anvil portion of end effector160 includes a cam surface for being engaged by the drive assembly ofend effector 160. The drive assembly includes a drive beam, whichdesirably has a knife for cutting tissue. The drive beam has a camroller positioned to engage the cam surface, and a flange positioned toengage the cartridge assembly to effect approximation of the anvilassembly 162 and cartridge assembly 164 with respect to one another whenthe drive beam is advanced distally. In addition, when advanced furtherin the distal direction, the drive beam engages an actuation member fordeploying the surgical fasteners from the cartridge assembly, asdisclosed in the Milliman 139 patent.

Any combination of sensors may be positioned within powered surgicalinstrument 100 to determine the position of various components and/orits operating stage, e.g., articulation, rotation, clamping, firing ofend effector 160. For example, limit switches, proximity sensors (e.g.,linear and/or ferromagnetic), potentiometers, linear variabledisplacement transducers (L VDT), shaft encoders, etc., may be used tohelp control and/or record the location of articulation linkage 244,firing rod 306 and/or ring gear 230, as discussed above.

Referring now to FIGS. 9, 11 and 12, endoscopic portion 140 includes atube housing 144 that extends from an area adjacent housing 110 towardsend effector 160. As drive tube 302 rotates, end effector 160 does notrotate as a direct consequence thereof. Referring to FIG. 13, tubehousing 144 includes flat portions 148 thereon, which correspond to flatportions 310 of firing rod 306. The pair of flat portions 148 and 310helps prevent rotation of firing rod 306 by helping to limit firing rod306 to axial movement.

With reference to FIG. 9, a drive motor shaft 218 is shown extendingfrom drive motor 210 and being connected to drive gear 200. A fastener(not explicitly shown in this embodiment) may be used to retain drivegear 220 on drive motor shaft 218. Drive motor shaft 218 is rotated bydrive motor 210, thus resulting in rotation of drive gear 220. Drivemotor shaft 218 is shown having a flat portion 219 (more than one flatportions 219 may be included), which allows “play” or “rotational float”between drive gear 220 and drive motor shaft 218 to facilitate toothalignment of the gears and to help enable drive gear 220 to shiftbetween positions. FIG. 9 also illustrates a bearing 308 disposed withinhousing 110 and at least partially surrounding drive tube 302. Bearing308 facilitates rotation of drive tube 302 and helps to align drive tube302 through endoscopic portion 140 and supports all thrust loadingbetween drive gear 200 and actuator gear 300.

In FIG. 10, a transducer 420 is shown adjacent drive motor 210 and shiftmotor 220. Transducer 420 (e.g., a force or pressure transducer) maymeasure and/or control the force required for the desired pressure onactuator gear 300. Transducer 420 may be in communication with portionsof user interface 120, which may provide feedback to a user.Additionally, spring coupling 430 is illustrated between drive motor 210and shift motor 220. Specifically, in a disclosed embodiment, springcoupling 430 includes a spring 432 mounted in a telescoping cage 434.Shift screw 222 is shown extending through spring 432 and may beconfigured to apply a compressive load on spring 432. It is envisionedthat cage 434 is collapsible as spring 432 is compressed. The forceapplied to drive motor 210 may be adjusted using spring 432 and/or cage434.

In an embodiment of the disclosure, drive gear 200 and actuator gear 300form a clutch face. The gear teeth are arranged to slip unless athreshold force is applied to drive motor 210 by shift motor 200 and aspring coupling 430 (as discussed below in connection with FIG. 10)disposed therebetween. Further, when shift motor 200 and spring coupling430 apply the threshold force needed for drive gear 200 and actuatorgear 300 to engage without slipping, rod 306 will be driven distally.Telescoping cage 434 may include a stop incorporated therewith, suchthat cage 434 will retract rod 306, rather than decompress springcoupling 430.

With reference to FIG. 3, user interface 120 is shown including screen122 and seven switches 124 a-124 g. In the illustrated embodiment, userinterface displays the “mode” (e.g., rotation, articulation oractuation), which may be communicated to user interface 120 via shiftsensor 224 (FIG. 4), “status” (e.g., angle of articulation, speed ofrotation, or type of actuation) and “feedback,” such as whether stapleshave been fired. Switch 124 a is shown having an “M,” standing for mode,which may be used to position drive gear 200 via shift motor 220 forselecting between rotation, articulation, grasping, clamping and firing.It is also envisioned that switch 124 a can be used to let a user inputdifferent tissue types, and various sizes and lengths of staplecartridges.

Switches 124 b-124 e on user interface 120 are shown with arrows thereonand may be used for selecting the direction, speed and/or torque atwhich drive gear 200 is rotated by drive motor 210. It is alsoenvisioned that at least one switch 124 can be used for selecting anemergency mode that overrides various settings, for example. Further,switches 124 f and 124 g are illustrated having an “N” and a “Y”thereon. It is envisioned that switches 124 f and 124 g may be used forhelping a user navigate and select various setting of powered surgicalinstrument 100. The indicia on switches 124 a-124 g and their respectivefunctions are not limited by what is shown in the accompanying figures,as deviations therefrom are contemplated and within the scope of thepresent disclosure. Additionally, and with reference to FIGS. 1 and 2,buttons 114 a and 114 b may be used for starting and/or stoppingmovement of drive motor 210 and/or shift motor 220. Other functions forbuttons 114 and 114 b are also anticipated as well as having more orfewer buttons 114. In a particular embodiment, switches 124 a-124 g mayinclude one or more microelectronic membrane switches, for example. Sucha microelectronic membrane switch includes a relatively low actuationforce, small package size, ergonomic size and shape, low profile, theability to include molded letters on the switch, symbols, depictionsand/or indications, and a low material cost. Further, switches 124 a-124g (such as microelectronic membrane switches) may be sealed to helpfacilitate sterilization of powered surgical instrument 100, as well ashelping to prevent particle and/or fluid contamination.

As an alternative to, or in addition to switches 124 or buttons 114,other input devices may include voice input technology, which mayinclude hardware and/or software incorporated in a digital controlmodule (DCM) 130 (FIG. 4), or a separate digital module connected to DCM130. The voice input technology may include voice recognition, voiceactivation, voice rectification and/or embedded speech. The user may beable to control the operation of the instrument in whole or in partthrough voice commands, thus freeing one or both of the user's hands foroperating other instruments. Voice or other audible output may also beused to provide the user with feedback.

In an embodiment, spring coupling 430 is used in the feedback andcontrol of powered surgical instrument 100. As described above, DCM 130may be connected to one or more buttons 114 or switches 124 and one ormore display screens 122 to provide feedback to the user and for helpingto control the operation of powered surgical instrument 100. DCM 130 maybe a digital board incorporated in housing 110 of powered surgicalinstrument 100. Spring coupling 430 may include a pressure transducerthat can interact with DCM 130 to control the force being applied to rod306.

It is also envisioned that user interface 120 includes different colorsand/or intensities of text on screen 122 and/or on switches 124 a-124 gfor further differentiation between the displayed items. User feedbackcan also be included in the form of pulsed patterns of light, acousticfeedback (e.g., buzzers, bells or beeps that may be sounded at selectedtime intervals), verbal feedback, and/or haptic vibratory feedback (suchas an asynchronous motor or solenoids), for example. The visual,auditory or haptic feedback can be increased or decreased in intensity.For example, the intensity of the feedback may be used to indicate thatthe forces on the instrument are becoming excessive. Additionally,switches 124 a-124 g may be positioned at different heights from oneanother and/or may include raised indicia or other textural features(e.g., concavity or convexity) to allow a user to depress an appropriateswitch 124 without the need to look at user interface 120. Further,proximal housing portion 110 b may be used as a joy stick type controlsystem.

Additionally, user interface 120 may include a separate display screenor screens 122 and input devices (such as switches 124 or buttons 114),or the input devices may be incorporated in whole or in part in screen122. For example, a touch screen liquid crystal display (LCD) may beused to allow the user to provide input while viewing operationalfeedback. The touch screen LCD may include resistive, capacitive orsurface acoustic wave controls. This approach may enable facilitation ofsealing screen 122 components to help sterilize powered surgicalinstrument 100, as well as preventing particle and/or fluidcontamination. In certain embodiments, screen 122 is pivotably orrotatably mounted to powered surgical instrument 100 for flexibility inviewing screen 122 during use or preparation. Screen 122 may be hingedor ball- and socket mounted to powered surgical instrument 100, forexample.

In a disclosed embodiment, at least some of the information monitored bythe various sensors in powered surgical instrument 100 may be providedto a video screen or monitoring system in an operating room. Forinstance, the data may be transmitted to a receiver for the operatingroom monitoring system from a communication transmitter incorporated inor associated with powered surgical instrument 100, via technologyincluding Blue Tooth, ANT3, KNX, Z Wave, XI0, wireless USB, WiFi, IrDa,Nanonet, Tiny OS, ZigBee, radio, UHF and VHF. Such features mayfacilitate monitoring by the user of powered surgical instrument 100 orother operating room or hospital personnel or remotely located persons.

Referring to FIG. 4, any combination of a battery pack 400, fuel celland/or high-energy capacitor may be used to provide power to poweredsurgical instrument 100. For example, capacitors may be used inconjunction with battery pack 400. Here, capacitors can be used for aburst of power when energy is desired/required more quickly than can beprovided with a battery on its own (e.g., when clamping thick tissue,rapid firing, clamping, etc.), as batteries are typically slow-draindevices from which current cannot be quickly drawn. It is envisionedthat batteries can be connected to capacitors to charge the capacitors.

It is also envisioned that battery pack 400 includes at least onedisposable battery. The disposable battery may be between about 9 voltsand about 30 volts and may be useful in a disposable surgicalinstrument. Other power-supplying means are also contemplated includingelectric power. In alternative embodiments a cord is provided to connectinstrument 100 to a generator.

In a disclosed embodiment, the DCM is connected to shift motor 220 anddrive motor 210 and is configured and arranged to monitor the battery400 impedance, voltage, temperature and/or current draw and to controlthe operation of powered surgical instrument 100. The load or loads onbattery 400, transmission, motors 220,210 and drive components ofpowered surgical instrument 100 are determined to control a motor speedif the load or loads indicate a damaging limitation is reached orapproached. For example, the energy remaining in battery 400, the numberof firings remaining, whether battery 400 must be replaced or charged,and/or approaching the potential loading limits of powered surgicalinstrument 100 may be determined.

The DCM can be configured and arranged to control or help control theoperation of shift motor 220 and/or drive motor 210 to respond to themonitored information. Pulse modulation, which may include an electronicclutch, may be used in controlling the output. For example, the DCM canregulate the voltage or pulse modulate the voltage to adjust the powerand/or torque output to prevent system damage or optimize energy usage.An electric braking circuit may be used for controlling drive motor 210and/or shift motor 220, which uses the existing back electromotive force(EMF) of rotating drive motor 210 to counteract and substantially reducethe momentum of drive gear 200. The electric braking circuit may improvethe control of drive motor 210 and/or shift motor 220 for stoppingaccuracy and/or shift location of powered surgical instrument 100.Sensors for monitoring components of powered surgical instrument 100 andto help prevent overloading of powered surgical instrument 100 mayinclude thermal-type sensors, such as thermal sensors, thermistors,thermopiles, thermocouples and/or thermal infrared imaging and providefeedback to the DCM. The DCM may control the components of poweredsurgical instrument 100 in the event that limits are reached orapproached and such control can include cutting off the power from thebattery pack 400, temporarily interrupting the power or going into apause mode, pulse modulation to limit the energy used, and the DCM canmonitor the temperature of components to determine when operation can beresumed. The above uses of the DCM may be used independently of orfactored with current, voltage, temperature and/or impedancemeasurements.

In the embodiment illustrated in FIG. 5, shift motor 220 is shownincluding a two-part housing 226. Each part 226 a and 226 b of two-parthousing 226 are slidably engaged with each other. It is envisioned thatpart 226 a is rigidly secured to drive motor casing 212, while part 226b is affixed to shift motor 220 and is translatable within housing 110.Additionally, a wiring slot 228 may be included to allow for wires (notexplicitly shown in this embodiment) to pass from transducer 420 towardsuser interface 120, for example (see also FIG. 10).

Referring to FIG. 14, powered surgical instrument 100 is illustratedhaving a pistol-grip handle portion 112. Here, handle portion 112 isdisposed at an angle (e.g., substantially 90°) from longitudinal axisA-A. In this embodiment, it is envisioned that at least one button 114is disposed thereon. Additionally, user interface 120 may be positionedapproximately in the position shown in FIG. 14. Further, a movablehandle (not explicitly shown in this embodiment) may be employed tocontrol various functions of powered surgical instrument 100.

It is envisioned that end effector 160 is reusable, can accept a staplecartridge and/or is part of a disposable loading unit. Further detailsof a disposable loading unit are described in detail in commonly-ownedU.S. Pat. No. 5,752,644 to Bolanos et al., the entire contents of whichare hereby incorporated by reference herein. Disposable and/orreplaceable loading units can include end effectors withoutarticulation, as disclosed in U.S. Pat. No. 6,953,139 to Milliman etal., previously incorporated by reference. A switch may be providedadjacent handle portion 112 to deactivate the second position of shiftmotor 220 electronically. Other means, such as mechanical means, mayalso be used.

A disposable or replaceable loading unit incorporating a surgical endeffector 160, in certain embodiments of the present disclosure, includessensors positioned within the loading unit to determine the position ofvarious components and/or operation of end effector 160, such asarticulation, rotation, clamping and firing of end effector 160. Forexample, electrical contacts, proximity sensors, optical sensors, photodiodes, and/or mechanical or metallic sensors are used to control and/orrecord information concerning the end effector 160. The location of theanvil assembly 162 and cartridge assembly 164 with respect to oneanother, the articulated or non-articulated position of end effector160, rotation of end effector 160, and/or correct loading of the loadingunit, staple cartridge and/or components of the staple cartridge mayalso be determined.

An identification system may also be included to determine andcommunicate to the DCM various information, including the speed, power,torque, clamping, travel length and strength limitations for operatingthe particular end effector 160. The DCM may also determine theoperational mode and adjust the voltage, clutch spring loading and stoppoints for travel of the components. More specifically, theidentification system may include a component (e.g., a microchip,emitter or transmitter) in end effector 160 that communicates (e.g.,wirelessly, via infrared signals, etc.) with the DCM, or a receivertherein. It is also envisioned that a signal may be sent via firing rod306, such that firing rod 306 functions as a conduit for communicationsbetween the DCM and end effector 160.

The loading unit, in certain embodiments according to the presentdisclosure, includes an axial drive assembly that cooperates with firingrod 306 to approximate anvil assembly 162 and cartridge assembly 164 ofend effector 160, and fire staples from the staple cartridge. The axialdrive assembly may include a beam that travels distally through thestaple cartridge and may be retracted after the staples have been fired,as disclosed in certain embodiments of U.S. Pat. No. 6,953,139 toMilliman et al., the disclosure of which is hereby incorporated byreference herein. By way of example, the sensors discussed above may beused to determine if the staples have been fired from the staplecartridge, whether they have been fully fired, whether and the extent towhich the beam has been retracted proximally through the staplecartridge and other information regarding the operation of the loadingunit. In certain embodiments of the present disclosure, the loading unitincorporates components for identifying the type of loading unit, and/orstaple cartridge loaded on the instrument 100, including infrared,cellular, or radio frequency identification chips (such as Sensormaticor similar technology). The type of loading unit and/or staple cartridgemay be received by an associated receiver within the DCM, or an externaldevice in the operating room for providing feedback, control and/orinventory analysis. The power or battery pack 400 can incorporate acomponent for identifying the type of power pack 400 loaded with poweredsurgical instrument 100 or for sending feedback concerning the status ofpower pack 400.

In certain embodiments of the present disclosure, powered surgicalinstrument 100 includes disposable or replaceable loading unitsincorporating a surgical end effector 160 and a reusable portionincluding a housing 110 and endoscopic portion 140 that is removablyattached to the loading unit. The reusable portion may be configured forsterilization and re-use in a subsequent surgical procedure. In anembodiment, the components of the housing 110 are sealed againstinfiltration of particulate and/or fluid contamination and help preventdamage of the component by the sterilization process. Power pack 400, incertain embodiments according to the present disclosure, comprises arechargeable battery. The rechargeable battery can be connected tocontacts accessible at housing 110 of the instrument 100, for example,or, rechargeable battery may be rechargeable through an inductivecharging interface sealed within housing 110. The inductive charginginterface may eliminate shorting of contacts and provides an internalbattery that may be hermetically or liquid resistance sealed.

The present disclosure also relates to a method of applying surgicalfasteners to tissue. The method includes the use of powered surgicalinstrument 100, as described above.

Now referring to FIGS. 16-19, a powered surgical instrument, e.g., asurgical stapler, in accordance with other embodiments of the presentdisclosure is referred to as reference numeral 1000. Powered surgicalinstrument 1000 includes a housing 1100, an endoscopic portion 1400defining a first longitudinal axis D-D extending therethrough, a shaftportion 1500 and an end effector 1600 defining a second longitudinalaxis E-E extending therethrough. Further details of powered surgicalinstrument 1000 are included in U.S. patent application Ser. No.11/786,933, filed on Apr. 13, 2007 (now U.S. Pat. No. 8,800,837), theentire contents of which are hereby incorporated by reference herein.While the features of the embodiments illustrated in FIGS. 16-19 areshown in connection with a particular type of surgical instrument 1000,it is envisioned that the features described with respect to FIGS. 16-19are operable with other surgical instruments, such as powered surgicalinstrument 100 of FIGS. 1-15.

With continued reference to FIG. 16, endoscopic portion 1400 extendsdistally from housing 1100, shaft portion 1500 is selectivelyconnectable to a distal end 1402 of endoscopic portion 1400 and endeffector 1600 is selectively connectable to an end 1502 of shaft portion1500. As shown in FIGS. 16-18, a plurality of different shaft portions1500 may be used with surgical instrument 1000 and a plurality ofdifferent end effectors 1600 may also be used with surgical instrument1000.

More specifically, a plurality of different shaft portions 1500 may beremovably connectable to endoscopic portion 1400, e.g., for a particularpurpose. It is envisioned that at least a portion of shaft portion 1500may be articulatable (FIG. 17A), curved (FIG. 17B) or made from acompliant material (for example, as illustrated in FIG. 17C).

As shown in FIGS. 16-18, a plurality of different classes of endeffectors 1600 may be removably connectable to shaft portion 1500 ofsurgical instrument 1000. It is envisioned that classes of end effectors1600 that are selectively connectable to distal end 1502 of shaftportion 1600 include those having a pivotable cartridge assembly (FIGS.16 and 19), a substantially circular cartridge assembly (FIGS. 17A, 17Band 17C) and parallel jaw members (FIG. 18). It is further envisionedthat different sub-classes of each class of end effector 1600 may beconnectable to shaft portion 1500.

For instance, within the class of end effectors 1600 including asubstantially circular cartridge assembly, sub-classes of such endeffectors 1600 include gastrointestinal anastomosis-type devices,transverse anastomosis-type devices (see, e.g. U.S. Pat. Nos. 4,520,817and 4,383,634) and circular anastomosis-type devices (see, e.g., U.S.Pat. No. 4,304,236). Gastrointestinal anastomosis-type devices areconfigured to drive and bend staples aligned in a row sequentially inrapid sequence, while transverse anastomosis-type devices drive and bendall staples simultaneously. Circular anastomosis-type devices areconfigured to simultaneously apply annular rows of staples to tissue.

Additionally, within the class of end effectors 1600 having a pivotablecartridge assembly, sub-classes may include end effectors 1600configured to drive staples sequentially and end effectors 1600configured to drive staples simultaneously.

It is therefore envisioned that a particular shaft portion 1500 may beconfigured for use with a particular class of end effectors 1600, suchas end effectors 1600 including a substantially circular cartridgeassembly. In such an embodiment, another shaft portion 1500 may beconfigured for use with another particular class of end effectors 1600,such as end effectors 1600 including a pivotable cartridge assembly orend effectors 1600 having parallel jaw members.

It is further envisioned that a particular shaft portion 1500 may beconfigured for use with a particular type of end effector 1600, such asend effectors 1600 configured for sequential firing of staples(including end effectors 1600 including a substantially circularcartridge assembly, end effectors 1600 including a pivotable cartridgeassembly or end effectors 1600 having parallel j aw members) or endeffectors 1600 configured for sequential firing of staples, for example.

Additionally, it is envisioned that a particular shaft portion 1500 maybe configured for use with several types of end effectors 1600,including end effectors 1600 including a substantially circularcartridge assembly, a pivotable cartridge assembly, parallel jawmembers, configured for sequential firing of staples and/or configuredfor sequential firing of staples. Here, a physician may select aparticular shaft portion 1500 based on other characteristics, such asshaft portion 1500 being articulatable, curved, or compliant, forexample.

At least one sensor 1700 may also be included on a portion of surgicalinstrument 1000. It is envisioned that a first sensor 1700 a is includedon endoscopic portion 1400, a second sensor 1700 b is included on shaftportion 1500, and a third sensor 1700 c is included on end effector1600. It is envisioned that sensors 1700 cooperate with each other forvarious purposes. For instance, first sensor 1700 a may be configured todetect the type of shaft portion 1500 that is engaged with endoscopicportion 1400 (e.g., by communicating with second sensor 1700 b).Further, second sensor 1700 b may be configured to detect the type ofend effector 1600 that is engaged with shaft portion 1500 (e.g., bycommunicating with third sensor 1700 c).

It is further envisioned that a user interface 1800 on housing 1100 isincluded. In a disclosed embodiment, user interface 1800 includes ascreen that displays at least some of the information (e.g., type ofshaft portion 1500 connected to endoscopic portion 1400, type of endeffector 1600 connected to shaft portion 1500, etc.) detected by sensors1700 in surgical instrument 1000. User interface 1800 may also display acondition of end effector 1600, such as angle of articulation orrotation, whether staples have been fired therefrom, if tissue isbetween jaw members, etc. This information may also be provided to avideo screen or monitoring system in an operating room. For instance,the data may be transmitted to a receiver for the operating roommonitoring system from a communication transmitter incorporated in orassociated with powered surgical instrument 1000, via technologyincluding Blue Tooth, ANT3, KNX, Z Wave, XI0, wireless USB, WiFi, IrDa,Nanonet, Tiny OS, ZigBee, radio, UHF and VHF.

The present disclosure also relates to a method of applying surgicalfasteners to tissue. The method includes the step of providing a poweredsurgical instrument 100, 1000, as described above. The method alsoincludes connecting shaft portion 1500 to distal end 1402 of endoscopicportion 1400 and connecting end effector 1600 to distal end 1502 ofshaft portion 1500.

It will be understood that various modifications may be made to theembodiments disclosed herein. For example, the locations along thelongitudinal axis for drive motor 210 and/or drive gear 200 may bedifferent than shown. Different types of gears for driving, rotation,articulation and/or actuation may be used. Therefore, the abovedescription should not be construed as limiting, but merely asexemplifications of various embodiments. Those skilled in the art willenvision other modifications within the scope and spirit of the claimsappended hereto.

1. (canceled)
 2. A surgical instrument comprising: an endoscopic portionincluding a first sensor; a shaft portion selectively securable to theendoscopic portion, the shaft portion including a second sensor; and anend effector selectively securable to the shaft portion, the endeffector including a third sensor, wherein the first, second, and thirdsensors are configured to cooperate with each other.
 3. The surgicalinstrument of claim 2, wherein the first sensor is configured to detecta type of the shaft portion.
 4. The surgical instrument of claim 2,wherein the first sensor communicates with the second sensor to detect atype of the shaft portion.
 5. The surgical instrument of claim 2,wherein the second sensor is configured to detect a type of the endeffector.
 6. The surgical instrument of claim 2, wherein the secondsensor communicates with third sensor to detect a type of the endeffector.
 7. The surgical instrument of claim 2, further including ahousing and a user interface on the housing, wherein the endoscopicportion extends from the housing.
 8. The surgical instrument of claim 7,wherein the user interface includes a screen that displays informationdetected by at least one of the first, second, or third sensor.
 9. Thesurgical instrument of claim 7, wherein the user interface displays acondition of the end effector.
 10. The surgical instrument of claim 9,wherein the condition of the end effector includes an angle ofarticulation or rotation, whether staples have been fired from the endeffector, or if tissue is between jaw members of the end effector. 11.The surgical instrument of claim 2, wherein the first sensor, the secondsensor, and the third sensor communicate wirelessly with each other. 12.The surgical instrument of claim 11, wherein the first sensor, thesecond sensor, and the third sensor are configured to communicate withan external monitoring system.
 13. A surgical instrument comprising: ahousing; an endoscopic portion extending from the housing, theendoscopic portion including a first sensor; a shaft portion selectivelysecurable to the endoscopic portion, the shaft portion including asecond sensor; and an end effector selectively securable to the shaftportion, the end effector including a third sensor, wherein the first,second, and third sensors are configured to cooperate with each other.14. The surgical instrument of claim 13, wherein the first sensor isconfigured to detect a type of the shaft portion.
 15. The surgicalinstrument of claim 13, wherein the first sensor communicates with thesecond sensor to detect a type of the shaft portion.
 16. The surgicalinstrument of claim 13, wherein the second sensor is configured todetect a type of the end effector.
 17. The surgical instrument of claim13, wherein the second sensor communicates with third sensor to detect atype of the end effector.
 18. The surgical instrument of claim 13,further including a user interface on the housing, wherein theendoscopic portion extends from the housing.
 19. The surgical instrumentof claim 19, wherein the user interface includes a screen that displaysinformation detected by at least one of the first, second, or thirdsensor.
 20. The surgical instrument of claim 13, wherein first sensor,the second sensor, and the third sensor communicate wirelessly with eachother.
 21. The surgical instrument of claim 20, wherein the firstsensor, the second sensor, and the third sensor are configured tocommunicate with an external monitoring system.